Miller Electric Big 40 CAT manual Control Box Assembly − CC/CV Models -1Item

Page 81

Item

Dia.

 

Part

Description

Quantity

No.

 

Mkgs.

 

No.

 

 

 

 

 

Figure 13-3. Control Box Assembly − CC/CV Models (Figure 13-1Item 106)

 

 

 

 

 

 

 

. . .

1

. . . F1, F2

. . *085 874 . .

FUSE, mintr cer slo-blo 10A 250V

. . . 2

. . .

2

.

. . . . . . . . .

. . .

046 432 . .

HOLDER, fuse mintr .250 x 1.250

. . . 2

. . . 3

.

. . . . . . . . .

. . .

201 077 . .

CONTROL BOX, lh

. . . 1

. . . 4

.

. . . . . . . . .

. . .

201 078 . .

CONTROL BOX, rh

. . . 1

. . .

5

.

. . . . . . . . .

. . .

201 079 . .

COVER, control box

. . . 1

. . .

6

.

. . . . . . . . .

. . .

134 201 . .

STAND-OFF, support pc card

. . . 3

. . .

7

. . . . PC9 . . .

192 224 . .

CIRCUIT CARD ASSY, display

. . . 1

. . . 8 . . . . . C9 .

. . .

. 087 110 . .

CAPACITOR, elctlt 240uf 200VDC

. . . 1

. . .

9

.

. . . . . . . . .

. . .

177 136 . .

CLAMP, capacitor 1.375dia

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

. 204 811 . .

HARNESS, control box, cv weld control (consisting of)

. . . 1

. . . 10

.

. . . SR1 . . .

035 704 . . .

. RECTIFIER, integ 40A 800V

. . . 1

. . . 11

.

. . . CR5 . . .

090 104 . . .

. RELAY, encl 12VDC SPST 30A/15VDC

. . . 1

. . . .

. .

.

. . . RC4 . . .

047 483 . . .

. CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . .

. . . 1

. . . .

. .

.

. . . RC3 . . .

158 466 . . .

. CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . .

. . . 1

. . . .

. . . . . . RC1 . . .

135 133 . . .

. CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg

. . . 1

. . . 12

 

CB11, 12, 13

139 266 . . .

. CIRCUIT BREAKER, man reset 1P 15A 250VAC frict

. . . 3

. . . .

. .

.

. . . . . . . . .

. . .

148 850 . . .

. SOCKET, relay 5 pin

. . . 1

. . . .

. .

.

. . . . S6 .

. . .

193 324 . . .

. SWITCH, rotary 6 position gold contacts

 

. . . .

. .

.

. . . . . . . . .

. . .

. . . . . . . . . . . .

. (located on front panel, see 13-5)

. . . 1

. . . .

. .

.

. . . . S5 .

. . .

. 011 609 . . .

. SWITCH,tgl spdt 15a 125vac on−none−on spd term chr

 

. . . .

. .

.

. . . . . . . . .

. . .

. . . . . . . . . . . .

. (located on front panel, see 13-5)

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

150 316 . . .

. CONN, rect univ 039 6p/s 3row plug cable lkg

. . . 6

. . . .

. .

.

. . . . . . . . .

. . .

177 859 . . .

. CONN, body 5 terminal (to engine control switch S1)

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

193 183 . . .

. CONN, rect cinch 18 pin

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

196 602 . . .

. PLUG, cavity 18,30 position cinch connector

. . . 4

. . . .

. .

.

. . . . . . . . .

. . .

196 603 . . .

. SEAL, switch 6 position rotary .250 shaft

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

141 450 . . .

. CONN, rect metrmate 10skt 1row plug cable lkg

. . . 1

. . . 13

.

. . . PC7

. . ♦195 706 . .

MODULE, pull to idle, two output, 7 pin

. . . 1

. . . 14

.

. . . CR4

. . ♦113 247 . .

RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg

. . . 1

. . . 15

.

. . . CR6 . .

♦090104 . .

RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg

. . . 1

. . . 16

.

. CR2, CR3 .

090 104 . .

RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg

. . . 2

. . . .

. .

.

. . . . . . . . .

. . .

212 452 . .

HARNESS, engine control (consisting of)

. . . 1

. . . 17 D10/C10, D11/C11 189 701 . . .

. DIODE/CAPACITOR BOARD

. . . 2

. . . 18

.

. . . . R8 .

. . .

217 335 . . .

. RESISTOR BOARD

. . . 1

. . . 19

.

. . . CB10

. . .

190 374 . . .

. CIRCUIT BREAKER, auto reset 12VDC 40A

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

148 850 . . .

. SOCKET, relay 5 pin

. . . 2

. . . .

. .

.

. . . PLG4

. . .

. 114 062 . . .

. CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg

. . . 1

. . . .

. .

.

. . . . . . . . .

. . .

185 655 . . .

. SEAL, wire univ 15P/S 3 row

. . . 1

. . . 20

.

. . . CR1 . . .

214 876 . . .

. RELAY, Encl 6vdc Spst 35a/14vdc 5 Pin

. . . 1

. . . 21

.

. . . CR9 . . .

090 104 . . .

. RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg

. . . 1

. . . 22

.

. . . CR8 . . .

155 309 . .

CONTACTOR, Solenoid 12vdc Continuous 400a Inrush

. . . 1

♦Optional

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

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OM-4406 Page 75

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Contents OM-4406 ProcessesDescription From Miller to You Table of Contents − Maintenance & Troubleshooting Directives StandardsDeccon111/02 Deccon1sound11/02 Sound Level InformationArc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions Starting Instructions + −Can cause severe burns. Do Are possible hazards asFalling equipment can cause Serious injury and damageReturn To Table Of Contents − 50 h Std Manufacturer’s Rating Labels For CE ProductsStd CC Models CC/CV ModelsSymbols And Definitions − Specifications Weld, Power, And Engine SpecificationsDimensions, Weights, And Operating Angles Volt-Ampere Curves For CC Models MIG Mode Stick ModeTIG Mode Volt-Ampere Curves For CC/CV ModelsDuty Cycle And Overheating Fuel ConsumptionOptional Three-Phase Generator Curves AC Generator Power Curve12 kVA/kW Single-Phase AC Output No Weld Load 15 kVA/kW Three-Phase AC Output No Weld LoadVolt-Ampere Curve For CC/CV Models In AC TIG Mode Installing Welding Generator See Sections 5-2And − InstallationLocation Grounding Airflow ClearanceUsing Lifting Eye Supporting The Unit Mounting Welding GeneratorMounting Surface To Bolt Unit In PlaceTools Needed 1/2 Installing Exhaust PipeStop engine and let cool Point exhaust pipe in desired diDo not overfill battery cells Activating The Dry Charge Battery If ApplicableRead and follow all instruc ChargerConnecting The Battery Reinstall cover after connecting batteryConnect Negative − Cable Last Engine Prestart Checks Coolant Recovery TankSelecting Weld Cable Sizes Connecting To Weld Output TerminalsSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsFront Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsDo not switch under load Engine Indicator LightsEngine Starting Controls To Start Do not use etherWeld Control/Arc Condition Information Label Remote Amperage Control On CC Models OptionalExample Set weld controls as shown toReturn To Table Of Contents Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV ModelsUse switch to select weld amperage range Voltage/Amperage Adjust Switch And Remote 14 ReceptacleEngine Oil Pressure Light Process/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsRemote Voltage/Amperage Control On CC/CV Models Optional Example Combination Remote Amperage Control StickExample Combination Remote Amperage Control TIG Volt And 240 Volt Receptacles − Operating Auxiliary EquipmentAt least once a month, run en Open, contact Factory AuthoThree-Phase Power Connection Rear Of PanelClose panel opening if no connections are made to generator Optional Generator Power Receptacles 240 V 15 a AC South African Receptacle RC1Circuit Breaker CB2 Circuit Breaker CB3 Maintenance Label − Maintenance & TroubleshootingEvery 8 h Routine MaintenanceEvery 50 h Every 100 hEvery 1000 h ServiceEvery 2000 h Caterpillar Customer AssistanceBy the warranty Servicing Air CleanerTo clean air filter Do not clean housing with air hoseInspecting And Cleaning Optional Spark Arrestor Muffler Stop engine and let cool. Reinstall cleanout plugTools Needed 3/8 Idle Speed Adjustment Adjusting Engine SpeedWeld/Power Speed Adjustment Engine Speed No LoadServicing Fuel And Lubrication Systems Overload Protection Pre-Start Diagnostic Checks Diagnosing Causes Of Engine Fault ShutdownsDiagnostic Checks While Running Start Engine With No Load AppliedWelding − CC Models TroubleshootingWelding − CC/CV Models Standard Generator Power Optional Three-Phase Generator Power CC/CV ModelsEngine Shutdown switch is released Out Wiring harness and componentsTemperature is too high see Sections 5-7and Air in fuel system. See engine manualCircuit Diagram For CC Welding Generator − Electrical Diagrams215 296-B Circuit Diagram For CC/CV Welding Generator 215 297-B − RUN-IN Procedure WetstackingWelding Generator Procedure at less than Run-In Procedure Using Load BankStop engine Do not touch hot exhaust From flammables Do not PerformBank/grid Run-In Procedure Using Resistance GridFrom flammables Do not perform run-inHas this symbol − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Use ground device as stated Electrical codesApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible− Parts List 117 116 103 102 115 FIG 114 105 104 101 120113 108 100 CC only 119 110 109 111 -4 or 85 Fig 51 52Dia Part Description Quantity Dia Part Description Quantity Mkgs 095 Control Box Assembly − CC Models Control Box Assembly − CC/CV Models Control Box Assembly − CC/CV Models -1Item Panel, Front w/Components − CC Models MS1 Panel, Front w/Components − CC/CV Models -1Item Panel, Front w/Components − CC/CV ModelsPC6 192 PLG6 34 36 27 26 Hardware is common Not available unless listedMain Rectifier Assembly -1Item Main Rectifier Assembly Page Support Your distributor also givesFor assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department
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